A test strategy for pre-reflow AOI: one high-volume OEM proves that even simple feedback from an AOI system can reduce end-of-line defects by an order of magnitude.(AUTOMATED OPTICAL INSPECTION)

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<a href="https://www.highbeam.com/doc/1G1-148960847.html" title="A test strategy for pre-reflow AOI: one high-volume OEM proves that even simple feedback from an AOI system can reduce end-of-line defects by an order of magnitude.(AUTOMATED OPTICAL INSPECTION) | HighBeam Research">A test strategy for pre-reflow AOI: one high-volume OEM proves that even simple feedback from an AOI system can reduce end-of-line defects by an order of magnitude.(AUTOMATED OPTICAL INSPECTION)</a>

Until recently, the use of pre-reflow optical inspection usually was limited to manufacturers with a very specific assembly problem or those on the cutting edge of process control who hoped to increase yields by earlier detection and problem-prevention. Now, even mainstream manufacturers are adopting pre-reflow inspection in a bid to reduce line setup time, end-of-line defects, and the costs associated with defects while keeping first-pass yields and reliability high.

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Manufacturers who implement pre-reflow optical inspection generally fall into one of four groups: those who build wireless products with RF shields, which typically are applied before the reflow oven and prevent 100% post-reflow optical inspection; those who build high-reliability products and need to do it right the first time; new product introduction centers that need to get paste-and-placement equipment up and running quickly and efficiently for each new board type; and those who believe that earlier detection and prevention will improve yields.

Manufacturers interested in process control wonder whether they need to be experts in statistical data analysis and process control procedures to get value from pre-reflow automated optical inspection (AOI) machines. The answer is that even simple feedback from a pre-reflow optical inspection system can produce dramatic results in tuning the process and keeping it under control.

One Manufacturer's Experience

This article chronicles one manufacturer's application of post-place/pre-reflow AOI over a five-month period. Prior to installing the Optima 7200 Post-Place/Pre-Reflow Optical Test System, roughly 10% of the boards built had a gross defect or major fault. The system was installed, and the results were carefully measured over several months.

The company, a major North American OEM manufacturer of car radios, used the new defect and measurement data from the AOI system to identify and repair the defects and perform simple placement-machine corrections. …

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